Aero Housewares GR900 Series User manual

Brand: Aero Housewares

Model: GR900 Series

Type: User manual

SM3120-18D Page 1 of 6 ©Aero-Motive Company Jul-01

Ground Fault Cable Retractor

GR900 Series

Service Manual

AERO-MOTIVE COMPANY

A Woodhead Industries, Inc. Subsidiary

IMPORTANT SAFETY INSTRUCTIONS

Please read this manual carefully and follow its instructions. Improper use or failure to follow these instructions could

result in serious injury, death or property damage. Operators should be instructed in the safe and proper use and

maintenance of this product. Keep this manual for future reference.

The following safety precautions call attention to potentially dangerous conditions.

DANGER:

Immediate hazards which WILL result in severe personal injury or death.

WARNING:

Hazards or unsafe practices which COULD result in severe personal injury or death.

CAUTION:

Hazards or unsafe practices which MAY result in minor personal injury or product or

property damage.

Model GR900 retracts up to 40 feet of #1/0 or #2/0 AWG grounding cable intended to protect equipment and personnel in

the event of a ground fault. The collector rings’ electrical path through the reel has a current carrying capacity greater

then that of the largest cable (#2/0 AWG) to be installed on the reel.

WARNING:

Failure to lock the cable drum in position with the cable fully extended as instructed, will

create an explosion hazard in the even of fault condition, and may result in property damage,

personal injury, or death.

WARNING:

The internal electrical path is not insulated from the reel frame, therefore, this reel is

unsuitable for other uses other than retracting ground cables. Use for other applications will

create an electrical shock hazard, and could result in property damage, personal injury, or

death.

WARNING:

Failure to install, operate, and maintain the retractor in accordance with these instructions

may result in electrical shock causing property damage, personal injury, or death.

WARNING:

If ground fault has occurred, return the reel to Aero-Motive Company for inspection , and

possible repair before placing back in service. Failure to do so could result in electrical

shock hazard, and may result in property damage, personal injury, or death.

Installation

CAUTION:

Misalignment of the reel and cable travel direction will cause the cable to be deflected at a

sharp angle around the cable guide rollers

CAUTION:

The reel should be bolted securely to a flat metal surface of sufficient strength and rigidity to

support it under all conditions to which it will be subjected. Mounting holes will

accommodate 7/16” or 3/8” bolts. Nothing smaller then 3/8” or 10mm bolts should be used.

SM3120-18D Page 2 of 6 © Aero-Motive Company Jul-01

MOUNTING

The fixed base of the reel allows mounting in several different positions including base up, base down, or

wall mounted. Here are general mounting requirements:

• Main-shaft must be horizontal.

• Centerline of the spool assembly must be on line with the cable run.

• When mounted overhead in base up position, add a secondary chain, bracket or other safety device

to prevent reel from falling in case the mounting bolts are removed or loosened from vibration.

INSTALLING CABLE

1. Select the proper cable size (#1/0 or #2/0 AWG) to fit the application. The cable should have fine

stranding for flexibility and a jacket suitable for rough handling.

2. After removing the outer drum half (29) pass the end of the cable through the neoprene cable seal

(30).

3. Adjust the neoprene cable seal (30) to fit the cable diameter by cutting away the smaller rings with a

sharp knife. The remaining hole size should be smaller then the cable diameter and must stretch

when

inserting the cable.

4. Finish the end of the cable by either stripping and thinning or applying a suitable pin connector.

5. Insert the cable end or pin connector through the diameter hole provided in the terminal on the rotating

portion of the slip ring assembly (27).

6. Lock the cable securely in place with the set screw and jam nut provided.

7. Clamp the cable to the inside of the inner drum half (33) using the two hole clamp (23), screws (25),

and washers (24). Provide slack between the cable termination on the slip ring assembly (27), and

the

cable clamp (23) to allow free alignment.

8. Reinstall the outer drum half (29) and drum gasket (26) with the four screws.

WARNING:

All steps related to termination of the cable must be followed carefully. Failure to properly

terminate the cable may result in property damage, personal injury, or death.

9. The cable can now be wound onto the cable drum.

10. A warning label (35) is provided with the retractor and must be attached to the free end of the cable

between the adjustable cable stop (34) and the point where the cable jacket is stripped off (see parts

drawing). To attach the label, remove the adhesive cover from the back and place the center of the

label on the center if the cable. Wrap the cable both ways from the center so both sides (if any re-

mains) adhere to each other, back to back. (See illustration)

If cable is replaced at a later date contact Aero-Motive Co. 1-800-999-8559 for replacement label.

SM3120-18D Page 3 of 6 © Aero-Motive Company Jul-01

SPRING TENSIONING

CAUTION:

Failure to test for adequate spring revolutions can cause spring damage. Hazards or

unsafe practices MAY result in minor personal injury or product or property damage.

NOTE: A minimum 2 pre-tension turns is required. Additional turns can added as long as one unused

spring turn remains when cable is completely extended. If entire cable cannot be pulled out,

decrease spring tension until full one turn remains.

All reels require pretensioning turns to spool assembly before connecting free end of working cable. Set

spring tension by turning fully wrapped reel through a specific number of revolutions or turns. Number of

pretension turns depends on application and desired tension. A minimum of 2 set up turns is needed

for most applications. Additional tension may be added by repeating above process. Failure to

pretension reel may result in insufficient tension to retract and may shorten spring life.

After cable is installed, apply the extra warning label (35) shipped with the reel, to the insulated cable that

protrudes beyond the cable stop.

CAUTION:

Check to make sure that the cable can still be pulled out without winding the main spring to

the end. If the cable can not be pulled out completely, too many prime turns have been

applied and some will have to be removed. Operating the reel with too many prime turns will

restrict the cable travel and shorten the life of the main spring.

CONNECTING GROUND

The ground connection cable should be as large or larger than the cable installed on the drum. It is

attached to the reel by connecting to the ½” diameter copper rod protruding beyond the junction box

cover

(11), on the base (3). Connection should be made with a commercial fitting specifically intended for

attaching this size cable to ½” diameter copper rod.

WARNING:

Failure to make mechanically and electrically sound connection at both ends of the cable will

create and electrical shock hazard and could result in property damage, personal injury, or

death.

ADJUSTING CABLE GUIDE

Cable guide position is set by rotating the spring pocket assembly. Loosen three clamps holding spring

pocket assembly in place by unscrewing three hex head bolts. Unless required, do not completely

remove bolts or clamps. Reposition guide as required, making sure clamps straddle ribs on outside

diameter of spring pocket assembly and retighten hex head bolts.

CAUTION: Pulling the cable at sharp angles to the cable guide will shorten the cable life and retard

retraction speed.

OPERATION

RATCHET LOCK

All reels are supplied with a ratchet lock to hold drum at any of several positions per drum

revolution and prevent if from retracting. If ratchet lock is not required--constant tension--, move spring

clip and spring to adjacent cable guide screw. To release ratchet, pull cable out until ratchet pawl

disengages.

GROUND FAULT CONNECTION

When the cable is pulled out and connected to provide ground fault protection, all of the cable should be

fully extended to provide maximum current capacity and a padlock must be installed on the reel through

the hole provided in the flange of the spool. This padlock prevents drum rotation and assures that the

cable remains unwound should a ground fault occur.

SM3120-18D Page 4 of 6 © Aero-Motive Company Jul-01

WARNING:

Failure to unwind the full length of cable and then padlock the spool to prevent its

inadvertent rewinding, in the event of a ground fault, will create an explosion hazard which

could result in property damage, personal injury, or death

WARNING:

Personnel should be kept at a safe distance from the Ground Fault Reel and Cable. In the

event of a ground fault, the sudden surge of power will cause the cable to move violently and

could cause property damage, personal injury, or death.

WARNING:

This reel is intended for use in a grounding circuit only. The electrical path is not insulated

from the reel frame. Property damage, personal injury, or death could result if retractor is

not used in accordance with this manual.

WARNING:

Check all electrical connections on retractor and ground cable terminations before use.

Failure to do so may result in shock hazard causing property damage, personal injury, or

death.

SERVICE

WARNING:

If ground fault condition has occurred, remove the reel from service immediately and return

it to Aero-Motive Company for inspection and, if necessary, repair. Failure to do so could

result in and electric shock hazard causing damage, personal injury, or death.

MAINSPRING REPLACEMENT

If the reel will not develop tension or retract cable, the spring assembly may need to be replaced.

To replace the mainspring:

1. Disconnect the input grounding connection.

2. Remove junction box cover (11) and connector (12).

3. Remove shaft retainer screw (1) and shaft retainer (2).

4. Remove drum and main shaft from base (3).

5. Remove cable guide (16), spring clip (20), both screws (19), extension spring (15), shoulder screw

(21), and ratchet pawl (22) from spring pocket assembly (14).

6. Remove spring pocket assembly (14) from base (3) and replace with new spring pocket assembly.

Assemble in reverse order.

WARNING:

Spring pocket assemblies are sealed to prevent disassembly. Don not attempt to remove

spring from its pocket. Uncontrolled release of spring tension may occur causing property

damage, personal injury, or death.

WARNING:

Carefully inspect all wire connections after any service work is conducted. Failure to do so

could result in property damage, personal injury, or death.

MAINTENANCE

ELECTRICAL

1. Inspect all cable connections at least monthly.

2. Resistance through the reel slip ring assembly should never exceed 0.001 ohms. If so, return to

Aero-Motive Company for inspection and repair.

NOTE: The slip ring assembly has been designed in such manner that it cannot be disassembled

SM3120-18D Page 5 of 6 © Aero-Motive Company Jul-01

REPLACEMENT PARTS

SM3120-18D Page 6 of 6 © Aero-Motive Company Jul-01

Reference

Number *

Part

Number Qty. Description

1 C03500231 1 SCREW; PAN HD. M5 X 12MM

2 M41100003 1 SHAFT RETAINER

3 H22110385 1 BASE

4 3 CLAMP-Included in clamp kit B below.

5 3 SCREW; HEX HD. M6 -Included in clamp kit B below.

6 M34370006 1 MAIN SHAFT, ELECTRICAL WELDING REEL

7 C47040141 1 O-RING

8 C34620105 1 THREAD PLUG

9 C71140112 1 NUT; ¾” NPT LOCKING

10 M14240007 1 JUNCTION BOX GASKET

11 H82640002 1 JUNCTION BOX COVER

12 C75620419 1 STRAIN RELIEF CONNECTOR, ¾” NPT .500

13 C03500253 10 SCREW; PAN HD. M6 X 16MM – Included in roller guide kit C below.

14 H41220076 1 SPRING POCKET ASSEMBLY

15 C60610121 1 EXTENSION SPRING

16 M04730007 1 CABLE GUIDE – Included in roller guide kit C below.

17 M24060125 4 ROLLER SHAFT – Included in roller guide kit C below.

18 M86700006 4 ROLLER – Included in roller guide kit C below.

19 C03500255 2 SCREW; PAN HD. M6 X 20MM

20 M53350002 1 SPRING CLIP

21 C15070225 1 SCREW; SHDR M8 X 10 X 16MM

22 M86750002 1 RATCHET PAWL

23 M70780007 1 CABLE CLAMP

24 C01070517 2 FLAT WASHER M5

25 C03500237 2 SCREW PAN HD M5

26 1 DRUM GASKET – Included in drum kit A below.

27 H96610001 1 SLIP RING ASS’Y, ELECTRIC WELDING REEL

28 4 SCREW – Included in drum kit A below.

29 1 OUTER DRUM HALF – Included in drum kit A below.

30 M86550002 1 CABLE SEAL

31 M37810027 1 SEAL COVER

32 C03500201 4 SCREW PAN HD. M4 X 12MM

33 1 INNER DRUM HALF – Included in drum kit A below.

34 STM2 1 CABLE STOP (ST2 KIT)

35 1 WARNING LABEL – Included in drum kit A below.

36 1 SLIP RING BRACKET – Included in drum kit A below.

37 2 SCREW; PAN HD. M8 X 16MM – Included in drum kit A below.

KIT A H05040005 AR DRUM KIT – (GR900) Includes items #’s 26, 28, 29, 33, 35, 36 & 37

KIT B H05040013 AR CLAMP KIT- STAINLESS STEEL- Includes 3 each of # 4 & 5.

KIT C H26340009 AR ROLLER GUIDE KIT – Includes item # 13, 16, 17, and 18.

Aero-Motive Company AKAPP Electro Industrie Woodhead Connectivity LTD. Woodhead Asia PTE LTD. Woodhead Canada LTD.

A Woodhead Industries Inc. Subsidiary

PO Box 2678

Kalamazoo, MI 49003-2678

(616) 337 7700

(800) 999 8559

FAX: (800) 333 6119

www.aeromotive.com

Nijverheidsweg 14 Box 54

NL-3771 ME Barneveld

NL-3771 AB Barneveld

Holland

(31) 34 241 4022

FAX: (31) 34 249 2384

www.akapp.com

Factory No. 9

Rassau Industrial Estate

Ebbw Vale Gwent NP3 5SD

United Kingdom

(0495) 35 0436

FAX: (0495) 35 0877

[email protected]

401 Commonwealth Drive #04-04

Haw Par Technocentre

Singapore 0314

(65) 261 6533

FAX: (65) 479 3588

[email protected]

1090 Brevik Place

Mississauga Ontario

L4W 3Y5 Canada

(905) 624-6518

FAX: (905) 624-9151

www.woodhead.ca

Aero Housewares GR900 Series User manual

Brand: Aero Housewares

Model: GR900 Series

Type: User manual

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Aero Housewares GR900 Series User manual

Aero Housewares GR900 Series User manual

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